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Improving Pumping System PerformanceA Sourcebook for Industry
Improving Pumping System PerformanceA Sourcebook for Industry
Second EditionSecond Edition
Improving Pumping System Performance
AcknowledgementsThis second edition of Improving Pumping System Performance: A Sourcebook for Industry was developed
by the U.S. Department of Energy’s Industrial Technologies Program (ITP) and the Hydraulic Institute (HI).
ITP undertook this project as part of a series of sourcebook publications on industrial equipment. Other topics
in this series include compressed air systems, fan and blower systems, motors and drives, steam systems, and
process heating systems. For more information about ITP and HI, see Section 4, “Where to Find Help.”
The Department of Energy, Lawrence Berkeley National Laboratory, the Alliance to Save Energy, and Resource
Dynamics Corporation wish to thank staff at the many organizations that so generously assisted in the collection
of data for this sourcebook. In addition, we would like to particularly recognize the following for their input and
Second Edition, May 2006
Prepared for the United States Department of Energy
Industrial Technologies Program
By
Lawrence Berkeley National Laboratory
Berkeley, California
Resource Dynamics Corporation
Vienna, Virginia
Alliance to Save Energy
Washington, D.C.
In cooperation with the Hydraulic Institute
Parsippany, New Jersey
Produced by the National Renewable Energy Laboratory
Golden, Colorado
Stefan M. Abelin, ITT Flygt Corporation
Robert Asdal, Hydraulic Institute
William Beekman, Floway Pumps
Heinz Block, P.E., Process Machinery Consulting
Steve Bolles, Process Energy Services
Karl Buscher, ITT Fluid Handling – Bell & Gossett
Don Casada, Diagnostic Solutions, LLC
Mick Cropper, Sulzer Pumps U.S. Inc.
Barry Erickson, Flowserve Corp.
Gunnar Hovstadius, Gunnar Hovstadius Consulting, LLC
Al Iseppon, Pentair Water
Steve Kratzke
Ross C. Mackay, Ross Mackay Associates Ltd.
William Marscher, Mechanical Solutions, Inc.
J. P. Messina, P.E.
Michael Pemberton, ITT IPG PumpSmart Control Solutions
Gregg Romanyshyn, Hydraulic Institute
Arnold Sdano, Fairbanks Morse Pump Company
Michael W. Volk, Volk Associates, Inc.
Trey Walters, Applied Flow Technology
A Sourcebook for Industry
Contents
i
Acknowledgements inside coverTable of Contents iList of Figures ii
Quick Start Guide 1
Section 1: Pumping System Basics 3Overview 3Pumping System Components 3Pumping System Principles 6
Section 2: Performance Improvement Opportunity Roadmap 11Overview 11The Fact Sheets 11
Assessing Pumping System Needs 13
Common Pumping System Problems 19
Indications of Oversized Pumps 25
Piping Configurations to Improve Pumping System Efficiency 29
Basic Pump Maintenance 33
Centrifugal Pumps 37
Positive Displacement Pump Applications 41
Multiple Pump Arrangements 43
Pony Pumps 47
Impeller Trimming 49
Controlling Pumps with Adjustable Speed Drives 51
Section 3: The Economics of Improving Pumping Systems 55Overview 55Conduct a Systems Assessment 55Analyze Life-Cycle Costs Before Making a Decision 62Sell Your Projects to Management 64
Section 4: Where to Find Help 69Overview 69DOE Industrial Technologies Program and BestPractices 69Hydraulic Institute 73Directory of Contacts 75Resources and Tools 76
Appendices 93Appendix A: Glossary of Basic Pumping System Terms 95Appendix B: Pumping System Assessment Tool (PSAT) 99Appendix C: Pumping Systems Tip Sheets 101Appendix D: Guidelines for Comments 117
Improving Pumping System Performance
List of Figures 91Figure 1. Typical Pumping System Components 4
Figure 2. Key to the Fact Sheets 12
Figure 3. Illustration of the Sensitivity of Flow to Changes in Backpressure 15
Figure 4. Drooping Performance Curve 15
Figure 5. Cavitation in a Centrifugal Pump 20
Figure 6. Two Types of Sealing Methods: Packing and Mechanical Seals 21
Figure 7. Common Pipe Configuration Problems and How To Correct Them 30
Figure 8. Flow Straighteners 31
Figure 9. Proper Support of Suction and Discharge Piping 31
Figure 10. Centrifugal Pump Performance Curves 37
Figure 11. Family of Pump Performance Curves 38
Figure 12. Performance Curves for Different Impeller Sizes 38
Figure 13. Performance Curves for a 4x1.5-6 Pump Used for Water Service 39
Figure 14. Multiple Pump Operation 44
Figure 15. Multiple-Speed Pump Performance Curves 45
Figure 16. Typical Tank Level Control 48
Figure 17. Effect of Impeller Trimming on Pump Performance 49
Figure 18. Effects of Reducing Speed on a Pump’s Operating Characteristics 52
Figure 19. Power Lost through a Bypass Line 52
Figure 20. Fluid Power Lost across a Throttle Valve 52
Figure 21. Using a Pump Performance Curve To Determine Power Draw 60
ii
A Sourcebook for Industry
This sourcebook is designed to provide pumping
system users with a reference that outlines oppor-
tunities for improving system performance. It is
not meant to be a comprehensive technical text
on pumping systems; rather, it provides practical
guidelines and information to make users aware
of potential performance improvements. Guidance
also included.
Throughout this sourcebook, performance and
of a “systems approach.” For cost-effective
operation and maintenance of pumping systems,
attention must be paid not just to individual pieces
of equipment but to the system as a whole. A
systems approach to optimizing a pumping system
analyzes both the supply and demand sides of the
system and how they interact, shifting the focus
from individual components to total system
performance.
Often, operators are so focused on the immediate
demands of equipment that they overlook the
eters affect this equipment? For example,
frequently replacing pump seals and bearings
can keep a maintenance crew so busy that they
overlook the system operating conditions that are
causing most (or all) of the problems.
A systems approach involves the following types
Establish current conditions and operating
parameters
Determine present and estimate future process
production needs
Gather and analyze operating data and develop
load duty cycles
Assess alternative system designs and
improvements
Determine the most technically and
economically sound options, taking into
consideration all of the subsystems
Implement the best option
Assess energy consumption with respect
to performance
Continue to monitor and optimize the system
Continue to operate and maintain the system
for peak performance.
To use a systems approach effectively, a pumping
system designer needs to understand system
fundamentals, know where opportunities for
improvements are commonly found, and have a
list of key resources that can help to identify and
implement successful projects. Therefore, this
sourcebook is divided into four main sections,
as outlined below.
Section 1. Pumping System BasicsIf you are not familiar with the basics of pumping
discussion of terms, relationships, and important
system design considerations. It describes key
factors involved in pump selection and system
design; it also provides an overview of different
types of pumps and their general applications.
Key terms and parameters used in selecting
with pumping systems, you might want to skip
this section and go straight to the next one.
Section 2. Performance Improvement Opportunity RoadmapThis section describes the key components of a
pumping system and opportunities to improve
the system’s performance. Also provided is a
system components and performance improve-
ment opportunities. A set of fact sheets describing
Quick Start Guide
Quick Start Guide
1
Improving Pumping System Performance
these opportunities in greater detail follows the
2. Common Pumping System Problems
5. Basic Pump Maintenance
6. Centrifugal Pumps
7. Positive Displacement Pump Applications
8. Multiple Pump Arrangements
Speed Drives
Section 3. The Economics of Improving Pumping Systems
determining the life-cycle costs of pumping
systems. Understanding life-cycle costs is
essential to identifying and prioritizing improve-
ment projects and presenting these projects
in terms that will gain management support.
Therefore, this section discusses life-cycle cost
components, ways to measure these costs, and
key success factors in prioritizing and proposing
improvement projects.
Section 4. Where To Find HelpSection 4 describes useful sources of assistance
that can help you learn more about pumping
systems and ways to improve their performance
descriptions of resources within the U.S. Depart-
ment of Energy (DOE) Industrial Technologies
Program (ITP) and the Hydraulic Institute and a
directory of associations and other organizations
involved in the pump marketplace. This section
also provides lists of helpful resources, such as
tools, software, videos, and workshops.
AppendicesThis sourcebook on improving pumping systems
includes four appendices. Appendix A is a
glossary of terms used throughout the pumping
system industry (and printed in bold type in parts
of this sourcebook). Appendix B describes the
Pumping System Assessment Tool (PSAT),
which can help you identify and prioritize energy
improvement projects for pumping systems.
Appendix C contains a series of pumping system
tip sheets. Developed by DOE, these tip sheets
are brief summaries of opportunities for improv-
systems. Appendix D includes a form for
submitting suggested improvements to this
sourcebook.
Quick Start Guide
2
A Sourcebook for Industry3
Section 1: Pumping System Basics
OverviewPumps are used widely in industry to provide
for processing, and to provide the motive force in
hydraulic systems. In fact, most manufacturing
plants, commercial buildings, and municipalities
rely on pumping systems for their daily operation.
In the manufacturing sector, pumps represent 27%
of the electricity used by industrial systems. In the
commercial sector, pumps are used primarily in
heating, ventilation, and air-conditioning (HVAC)
systems to provide water for heat transfer. Mun-
icipalities use pumps for water and wastewater
transfer and treatment and for land drainage. Since
they serve such diverse needs, pumps range in size
from fractions of a horsepower to several thousand
horsepower.
In addition to an extensive range of sizes, pumps
also come in several different types. They are
positive displacement pumps
directly; centrifugal pumps (also called “roto-
this kinetic energy to pressure. Within these
Positive displacement pumps include piston, screw,
sliding vane, and rotary lobe types; centrifugal
pumps include axial
radial types. Many factors go into determining
which type of pump is suitable for an application.
Often, several different types meet the same
service requirements.
Pump reliability is important—often critically so.
In cooling systems, pump failure can result in
equipment overheating and catastrophic damage.
In lubrication systems, inadequate pump
performance can destroy equipment. In many
petrochemical and power plants, pump downtime
can cause a substantial loss in productivity.
Pumps are essential to the daily operation of many
facilities. This tends to promote the practice of
sizing pumps conservatively to ensure that the
needs of the system will be met under all
conditions. Intent on ensuring that the pumps are
large enough to meet system needs, engineers
often overlook the cost of oversizing pumps and
err on the side of safety by adding more pump
capacity. Unfortunately, this practice results in
higher-than-necessary system operating and
maintenance costs. In addition, oversized pumps
typically require more frequent maintenance
increases the wear and tear on system components,
resulting in valve damage, piping stress, and
excess system operation noise.
Pumping System Components
and end-use equipment (e.g., heat exchangers,
tanks, and hydraulic equipment). A typical
pumping system and its components are illustrated
PumpsAlthough pumps are available in a wide range of
types, sizes, and materials, they can be broadly
earlier—positive displacement and centrifugal.
These categories relate to the manner in which the
collapsing volume action, essentially squeezing an
of the system with each piston stroke or shaft
rotation. Centrifugal pumps work by adding
impeller.
pump, the kinetic energy
into pressure.
Section 1: Pumping System Basics
4Improving Pumping System Performance
Figure 1. Typical Pumping System Components
Although many applications can be served by
both positive displacement and centrifugal pumps,
centrifugal pumps are more common because they
are simple and safe to operate, require minimal
maintenance, and have characteristically long
operating lives. Centrifugal pumps typically suffer
less wear and require fewer part replacements
than positive displacement pumps. Although the
packing or mechanical seals must be replaced
periodically, these tasks usually require only a
minor amount of downtime. Centrifugal pumps
can also operate under a broad range of conditions.
The risk of catastrophic damage due to improper
valve positioning is low, if precautions are taken.
relationship. A centrifugal pump acting against a
does when acting against a low system pressure.
is described by a performance curve that plots
Understanding this relationship is essential to
properly sizing a pump and designing a system
see the fact sheet in Section 2 titled Centrifugal
Pumps.
In contrast, positive displacement pumps have a
to their speed. The pressures they generate are
determined by the system’s resistance to this
advantages that make them more practical for
certain applications. These pumps are typically
more appropriate for situations in which the
A
KeyPumpLevel IndicatorsTank, Liquid SupplyPump MotorMotor ControllerThrottle ValveBypass ValveHeat Exchangers(End-Use Equipment)
Instrumentation LinePump Discharge PipingPump Suction Piping
ABCDEFGH
IJK
A
B
C
D
E
F
G
H I
J
K
Section 1: Pumping System Basics
A Sourcebook for Industry5
The system requires high-pressure,
The pump must be self-priming
high shear forces
controlled
A disadvantage is that positive displacement
pumps typically require more system safeguards,
such as relief valves. A positive displacement
pump can potentially overpressurize system piping
and components. For example, if all the valves
downstream of a pump are closed—a condition
known as deadheading—system pressure will
ruptures, or the pump motor stalls. Although
relief valves are installed to protect against such
damage, relying on these devices adds an element
of risk. In addition, relief valves often relieve
a problem for systems with harmful or dangerous
of pump, see the fact sheet in Section 2 titled
Positive Displacement Pump Applications.
Prime MoversMost pumps are driven by electric motors.
Although some pumps are driven by direct current
(dc) motors, the low cost and high reliability of
alternating current (ac) motors make them the
most common type of pump prime mover. In
recent years, partly as a result of DOE’s efforts,
improved. A section of the Energy Policy Act
standards for most common types of industrial
provided industrial end users with greater selection
In addition, the National Electrical Manufacturers
Association (NEMA) has established the NEMA
PremiumTM
which is endorsed by the Hydraulic Institute; the
EPAct. In high-run-time applications, improved
operating costs. However, it is often more
effective to take a systems approach that uses
proper component sizing and effective mainten-
ance practices to avoid unnecessary energy
consumption.
A subcomponent of a pump motor is the motor
controller. The motor controller is the switchgear
that receives signals from low-power circuits,
such as an on-off switch, and connects or dis-
connects the high-power circuits to the primary
power supply from the motor. In dc motors, the
motor controller also contains a sequence of
switches that gradually builds up the motor
current during start-ups.
In special applications, such as emergency
lubricating oil pumps for large machinery, some
pumps are driven by an air system or directly
from the shaft of the machine. In the event of a
power failure, these pumps can still supply oil
to the bearings long enough for the machine to
service pumps are driven by diesel engines to
allow them to operate during a power outage.
Piping
from the pump to the point of use. The critical
aspects of piping are its dimensions, material type,
and cost. Since all three aspects are interrelated,
as the pipe diameter gets larger; however, larger
cost more than smaller pipe. Similarly, in systems
that operate at high pressures (for example,
hydraulic systems), small-diameter pipes can have
thinner walls than large-diameter pipes and are
easier to route and install.
this can be especially problematic in systems with
Section 1: Pumping System Basics
6Improving Pumping System Performance
operate at higher liquid velocity, increasing
erosion effects, wear, and friction head. Increased
friction head affects the energy required for
pumping.
Valves
by valves. Some valves have distinct positions,
either shut or open, while others can be used to
valves; selecting the correct valve for an appli-
cation depends on a number of factors, such as
ease of maintenance, reliability, leakage tenden-
cies, cost, and the frequency with which the
valve will be open and shut.
Valves can be used to isolate equipment or regu-
a part of a system for operating purposes or main-
through a system branch (throttle valve) or allow
resistance across it. In contrast, a bypass valve
in only one direction, thus protecting equipment
from being pressurized from the wrong direction
direction. Check valves are used at the discharge
pump is stopped.
End-Use Equipment (Heat Exchangers, Tanks, and Hydraulic Equipment)The essential purpose of a pumping system may be to provide cooling, to supply or drain a tank or reservoir, or to provide hydraulic power to a machine. Therefore, the nature of the end-use equipment is a key design consideration in determining how the piping and valves should
needs and pressure drops across this equipment
critical performance characteristic; for hydraulic
machinery, pressure is the key system need. Pumps and pumping system components must
of the end-use processes.
Pumping System PrinciplesDesign Practices
Fluid system designs are usually developed to
support the needs of other systems. For example,
in cooling system applications, the heat transfer
requirements determine how many heat exchan-
gers are needed, how large each heat exchanger
capabilities are then calculated based on the
system layout and equipment characteristics. In
other applications, such as municipal wastewater
removal, pump capabilities are determined by the
amount of water that must be moved and the
height and pressure to which it must be pumped.
system or service.
After the service needs of a pumping system are
and valve requirements must be engineered.
Selecting the appropriate type of pump and its
speed and power characteristics requires an
understanding of its operating principles.
The most challenging aspect of the design process
is cost-effectively matching the pump and motor
characteristics to the needs of the system. This
process is often complicated by wide variations
system needs are met during worst-case con-
ditions can cause designers to specify equipment
that is oversized for normal operation. In addition,
specifying larger than necessary pumps increases
material, installation, and operating costs. Design-
ing a system with larger piping diameters might
reduce pumping energy costs, however. See the
fact sheet titled
in Section 2 and the tip
sheet in Appendix C titled Reduce Pumping Costs
Section 1: Pumping System Basics
A Sourcebook for Industry7
Fluid EnergyFor practical pump applications, the energy of a
head.
Head is usually expressed in feet or meters,
which refers to the height of a column of system
energy. This term is convenient because it
incorporates density and pressure, which allows
centrifugal pumps to be evaluated over a range
rate, a centrifugal pump will generate two
different discharge pressures for two different-
these two conditions is the same.
(gauge pressure), height (or potential energy),
and velocity head (or kinetic energy).
Static pressure, as the name indicates, is the
quantity measured by conventional pressure
substantial impact on the static pressure in a
system, but it is itself a distinct measurement of
vented tank reads atmospheric pressure. If this
tank is located 50 feet (ft) above the pump,
however, the pump would have to generate at
least 50 ft of static pressure (for tap water, the
square inch [psi]) to push water into the tank.
Velocity head (also known as “dynamic head”)
systems, the velocity head is small in com-
velocity in cooling systems does not typically
is water, this velocity head translates to about
gauges, when designing a system, and when
evaluating a reading from a pressure gauge,
especially when the system has varying pipe
sizes. A pressure gauge downstream of a pipe
reduction will read lower than one upstream of the
reduction, although the distance may only be
a few inches.
Fluid Properties In addition to being determined by the type of
system being serviced, pump requirements are
viscosity, density, particulate content, and vapor
pressure. Viscosity is a property that measures the
as cold lubricating oil (at less than 60°F), are
move them effectively. As a result, the range of
motor combination that is appropriately sized for
oil at a temperature of 80°F may be undersized for
operation at 60°F.
The quantities and properties of particulates in a
Some pumps cannot tolerate much debris. And the
performance of some multistage centrifugal pumps
become eroded. Other pumps are designed for use
way they operate, centrifugal pumps are often used
as coal slurries.
The difference between the vapor pressure of a
mental factor in pump design and selection.
characteristic of centrifugal pumps—creates a
drop in static pressure. This drop can lower the
from a liquid to a vapor. Known as cavitation,
this effect can severely impact a pump’s
cavitation, tiny bubbles form. Since vapor takes
Section 1: Pumping System Basics
8
Section 1: Pumping System Basics
Improving Pumping System Performance
The damaging aspect of cavitation occurs when
these vapor bubbles return to liquid phase in a
violent collapse. During this collapse, high-
velocity water jets impinge onto surrounding
surfaces. The force of this impingement often
exceeds the mechanical strength of the impacted
surface, which leads to material loss. Over time,
cavitation can create severe erosion problems in
pumps, valves, and pipes.
Other problems that cause similar damage are
suction and discharge recirculation. Suction
patterns that result in cavitation-like damage in the
suction region of an impeller. Similarly, discharge
patterns in the outer region of an impeller. These
recirculation effects usually result from operating
type of damage, many pumps are listed with a
System TypesLike pumps, pumping system characteristics and
general as either closed-loop or open-loop
around a path with common beginning and end
points. An open-loop system has an input and an
another. Pumps that serve closed-loop systems,
such as a cooling water system, typically do not
have to contend with static head loads unless there
are vented tanks at different elevations. In closed-
loop systems, the frictional losses of system piping
and equipment are the predominant pump load.
In contrast, open-loop systems often require
pumps to overcome static head requirements as a
result of elevation and tank pressurization needs.
A mine dewatering system is one example; it uses
pumps to move water from the bottom of a mine
up to the surface. In this case, static head is often
the dominant pump load.
Principles of Flow Control Flow control is essential to system performance.
to satisfy system requirements; this creates a
tendency to oversize pumps and the motors that
control devices to regulate temperature and protect
equipment from overpressurization, oversizing
devices with high energy dissipation loads.
There are four primary methods for controlling
valves, bypass valves, pump speed control, and
multiple pump arrangements. The appropriate
power curve, the system load, and the system’s
can move through the valve, creating a pressure
drop across it. Throttle valves are usually more
shut, they maintain upstream pressure that can help
component. A major drawback of bypass valves is
In static-head-dominated systems, however, bypass
or systems with adjustable speed drives (ASDs).
Pump speed control includes both mechanical and
electrical methods of matching the speed of the
ASDs, multiple-speed pumps, and multiple pump
control options, especially in systems that are
dominated by friction head, because the amount
directly from the system demand. Pump speed
control is especially appropriate for systems in
which friction head predominates.
Both ASDs and multiple-speed motors provide
A Sourcebook for Industry9
Section 1: Pumping System Basics
different speeds according to system needs. During
a period of low system demand, the pump is
operated at low speeds. The primary functional
difference between ASDs and multiple-speed
motors is the degree of speed control available.
ASDs typically modify the speed of a single-speed
motor through mechanical or electrical methods,
while multiple-speed motors contain a different set
of windings for each speed. ASDs are practical for
continuously. For more information, see the fact
sheet in Section 2 titled
Adjustable Speed Drives.
Multiple-speed motors are practical for systems in
discrete levels that feature lengthy periods of
operation. One of the drawbacks to multiple-speed
motors is the added cost of equipment. Since each
speed has its own set of motor windings, multiple-
speed motors are more expensive than single-
speed motors. Also, multiple-speed motors are
Multiple pump arrangements typically consist
of pumps placed in parallel in one of two basic
uration, or a series of identical pumps placed in
the small pump, often called the “pony pump,”
operates during normal conditions. The large
pump is used during periods of high demand.
Because the pony pump is sized for normal system
large pump to handle loads far below its optimum
capacity. For more information on this type of
pump, see the Section 2 fact sheet titled Pony
Pumps.
With a series of identical pumps placed in parallel,
the number of operating pumps can be changed
according to system demands. Because the pumps
are the same size they can operate together,
serving the same discharge header. If the pumps
were different sizes, the larger pumps would tend
to dominate the smaller pumps and could cause
selected, each pump can operate closer to its
remains the same whether one or several pumps
are operating; what changes is the operating point
along this system curve.
Multiple pumps in parallel are well suited for
systems with high static head. Another advantage
is system redundancy; one pump can fail or be
taken off line for maintenance while the other
pumps support system operation. When identical
parallel pumps are used, the pump curves should
remain matched; therefore, operating hours should
be the same for each pump, and reconditioning
should be done at the same time for all of them.
the fact sheet in Section 2 titled Multiple Pump
Arrangements.
System Operating Costs
Fluid power = HQ (s.g.)
where
H = head (ft)
s.g. =
power in terms of horsepower.
The motor power required to generate these head
power by the pump shaft power; for directly
brake horsepower (bhp) of the motor.
operating point of centrifugal pumps at which
best
function of many design characteristics. Operating
a pump at or near its BEP not only minimizes
10
Section 1: Pumping System Basics
Improving Pumping System Performance
energy costs, it also decreases loads on the pump
and maintenance requirements.
incur high operating and maintenance costs relative
in high-run-time, oversized systems can add
ensuring system reliability. For more information
on oversized pumps, see the fact sheet in Section 2
titled . The Pump-
ing System Assessment Tool (see Appendix B)
provides assistance in identifying and prioritizing
projects to reduce the amount of energy used by
pumping systems.
The cost of oversizing pumps extends beyond
by a valve, a pressure-regulating device, or the
system piping itself, which increases system wear
and maintenance costs. Valve seat wear, which
problem and can shorten the interval between
valve overhauls. Similarly, the noise and vibration
welds and piping supports; in severe cases, this
can erode pipe walls.
Note that, when designers try to improve a
pumping system’s reliability by oversizing
equipment, usually the unanticipated result is
less system reliability. This is caused by both
the additional wear on the equipment and low-
A Sourcebook for Industry11
Section 2: Performance Improvement Opportunity Roadmap
OverviewCost-effective operation and maintenance of a
pumping system require attention to the needs of
both individual equipment and the entire system.
Often, operators are so focused on the immediate
demands of the equipment that they forget to step
back and notice how certain system parameters are
affecting this equipment.
A systems approach analyzes both supply and
demand sides of the system and how they interact,
shifting the focus from individual components to
total system performance. This approach usually
involves the following types of interrelated
Establish current conditions and operating
parameters
Determine present process production needs
and estimate future ones
Gather and analyze operating data and develop
load duty cycles
Assess alternative system designs and
improvements
Determine the most technically and
economically sound options, taking into
consideration all subsystems
Implement the best option
Assess energy consumption with respect to
performance
Continue to monitor and optimize the system
Continue to operate and maintain the system
for peak performance.
Section 2: Performance Improvement Opportunity Roadmap
The Fact Sheets
address both component and system issues. Each
to improve the performance of an industrial
1. Assessing Pumping System Needs
2. Common Pumping System Problems
3. Indications of Oversized Pumps
4. Piping Configurations to Improve Pumping System Efficiency
5. Basic Pump Maintenance
6. Centrifugal Pumps
7. Positive Displacement Pump Applications
8. Multiple Pump Arrangements
9. Pony Pumps
10. Impeller Trimming
11. Controlling Pumps with Adjustable SpeedDrives
12
Section 2: Performance Improvement Opportunity Roadmap
Improving Pumping System Performance
Key
A - Piping Configurat
B - Controlling Pump
C - Basic Pump Main
D - Common Pumpin
E - General Pump FaIndications of OveApplications, Cen
Figure 2. Key to the